Thermocouple assembly

ABSTRACT

A thermocouple assembly includes a thermocouple; a plurality of lead wires extending from the thermocouple; an insulating jacket extending along and enclosing the plurality of leads; and at least one internally sealed area within the insulating jacket to prevent fluid leakage along and within the insulating jacket. The invention also provides a method of preventing leakage of a fluid along and through an insulating jacket of a thermocouple including the steps of a) attaching a plurality of lead wires to a thermocouple; b) adding a heat sensitive pseudo-wire to extend along the plurality of lead wires; c) enclosing the lead wires and pseudo-wire inside an insulating jacket; d) locally heating axially spaced portions of the insulating jacket to a temperature which melts the pseudo-wire and fuses it with an interior surface of the jacket.

This is a divisional of application Ser. No. 09/395,619, filed Sep. 14, 1999, now pending, the entire content of which is hereby incorporated by reference in this application.

This invention was made with Government support under Contract No. DE-FC21-95MC31176 awarded by the Department of Energy. The Government has certain rights in this invention.

BACKGROUND OF THE INVENTION

This invention relates to thermocouple assemblies and particularly those that are used inside lubricated components such as turbine bearings. Specifically, the invention relates to a unique insulating jacket and thermocouple lead arrangement which prevents leakage of lubricating medium through the thermocouple jacket.

During the installation and routing of a thermocouple in, for example, a gas turbine bearing housing, the insulating jacket of the thermocouple can be cut or skinned. Any opening in the insulation jacket during installation permits lubricant such as oil within the bearing housing to leak through the outer insulating jacket and along the internal wires or leads. The oil can flow all the way to a junction box where the thermocouple leads are connected to terminal boards. The oil leakage may even be sufficient to flood the board and cause malfunction of the thermocouple readings. While this problem can be fixed easily if the opening in the insulation jacket is located outside the bearing housing, repair proves problematic in the event the cut or tear is inside the bearing housing, requiring an expensive and time consuming tear-down of the bearing and attendant shut-down of the turbine.

BRIEF SUMMARY OF THE INVENTION

This invention solves the problem of internal leakage of fluid through the thermocouple insulating jacket by introducing a silicone (or other epoxy) “pseudo-wire” into the assembly process during manufacture of the thermocouple. The “pseudo-wire” (preferably silicone) extends through the insulated jacket along and among the thermocouple leads. The thermocouple is then locally heated to a temperature which melts the silicone wire inside the thermocouple jacket and fuses it to the inside wall of the jacket. These localized fused areas may be about 12 inches in length and spaced apart by intervals of about 24 inches. Each of these fused areas provides a blockage to potential oil leaks caused by a cut or tear in the outer insulating jacket of the thermocouple.

Accordingly, in its broader aspects, the present invention relates to a thermocouple assembly comprising a thermocouple; a plurality of lead wires extending from the thermocouple; an insulating jacket extending along and enclosing the plurality of leads; and at least one internally sealed area within the insulating jacket to prevent fluid leakage along and within the insulating jacket.

In another aspect, the invention relates to a machine component housing having a lubricant therein and a thermocouple assembly mounted in a wall of the housing, the thermocouple assembly comprising: a thermocouple; a plurality of lead wires extending from the thermocouple; an insulating jacket extending along and enclosing the plurality of leads; and at least one internally sealed area within the insulating jacket to prevent fluid leakage along and within the insulating jacket.

In still another aspect, the invention relates to a method of preventing leakage of a fluid along and through an insulating jacket of a thermocouple comprising the steps of: a) attaching a plurality of lead wires to a thermocouple; b) adding a heat sensitive pseudo-wire to extend along the plurality of lead wires; c) enclosing the lead wires and pseudo-wire inside an insulating jacket; d) locally heating axially spaced portions of the insulating jacket to a temperature which melts the pseudo-wire and fuses it with an interior surface of the jacket.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic diagram of a conventional thermocouple assembly;

FIG. 2 is a schematic diagram of a thermocouple assembly mounted in a wall or turbine bearing housing, with the thermocouple leads extending to a terminal board; and

FIG. 3 is an enlarged partial elevation of a thermocouple assembly in accordance with an exemplary embodiment of the invention.

DETAILED DESCRIPTION OF THE INVENTION

With reference to FIG. 1, a conventional thermocouple assembly 10 includes a thermocouple 12 along with a plurality of leads 14, 16, 18 and 20. The leads are enclosed within a flexible, extruded insulating jacket 22 which may be made of Teflon® or other suitable material.

If a cut or tear 24 is inadvertently made in the insulating jacket 22 during installation of the thermocouple at a location within, for example, a lubricated bearing housing 26 (see FIG. 2), the lubricating oil within the bearing may enter the jacket and flow in the direction of arrow 28. This oil may flow the entire length of the thermocouple leads (which may be 60 feet or more) and flood the terminal board 30, thus causing erroneous thermocouple readings, and requiring an expensive and time consuming shutdown.

FIG. 3 illustrates an exemplary embodiment of this invention where a silicone or other suitable epoxy pseudo-wire is added to the thermocouple assembly during manufacture. For convenience, reference numerals are used in FIG. 3 which correspond to those used in FIG. 1, but with the prefix “1” added. Thus, the thermocouple assembly 110 includes a thermocouple (not shown) and a plurality of leads 114, 116, 118 and 120 enclosed within an insulating jacket 122. The silicone “pseudo-wire” 132 added during manufacture of the assembly runs along and between the thermocouple leads 114, 116, 118 and 120, for substantially the entire length of the jacket. After the introduction of the silicone wire 132, the jacket 122 is externally heated at spaced locations along its length to a temperature of about 200° F. to melt the wire 132 and fuse the melted material to the interior surface of the jacket 122. One such fused portion is shown at 134 in FIG. 3. If necessary, an etching material can be added to the Teflon® jacket material as it is extruded to thereby enhance the bond between the melted “pseudo-wire” and the jacket. The fusing process results in adjacent areas ballooning slightly outwardly as shown at 136 and 138. These localized fused areas 134 may be about 12 inches in length, and may be axially spaced by about 24 inches, but these dimensions may vary depending on the particular thermocouple application. Each fused area 134 provides an internally sealed area, blocking the potential flow of oil caused by skinning or tearing the outer insulating jacket during thermocouple installation. In other words, oil entering the jacket 122 from a tear 124 in the jacket 122 (flowing in the direction of arrow 128) will not be able to reach the terminal board 30 (FIG. 2) because of the multiple seals formed along the length of the jacket.

It will be appreciated that the thermocouple assembly design as described herein not only prohibits oil leaking between the outer insulation jacket and the internal wires from the bearing to the junction box, but also allows operators to easily strip the jacket and connect the wires to the terminal boards due to its unique “balloon” configuration, i.e., the diameters of the unsealed areas 136, 138 are greater than the diameters of the sealed areas 134.

While the invention has been described in connection with what is presently considered to be the most practical and preferred embodiment, it is to be understood that the invention is not to be limited to the disclosed embodiment, but on the contrary, is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the appended claims. 

What is claimed is:
 1. A thermocouple assembly comprising: a thermocouple; a plurality of lead wires extending from said thermocouple; an insulating jacket extending along the length and enclosing said plurality of leads; and at least one internally sealed area within said insulating jacket to prevent fluid leakage along and within said insulating jacket wherein areas of said insulating jacket adjacent said at least one internally sealed area have greater diameters than the internally sealed area.
 2. The assembly of claim 1 wherein said at least one internally sealed area comprises a plurality of internally sealed areas at longitudinally spaced locations along said insulating jacket.
 3. The assembly of claim 2 wherein said plurality of internally sealed area are formed by locally heated and subsequently melted portions of an additional wire extending along and within said insulating jacket.
 4. The assembly of claim 2 wherein said additional wire comprises a silicone wire.
 5. The assembly of claim 2 wherein said additional wire comprises an epoxy wire.
 6. The assembly of claim 3 wherein said plurality of internally sealed areas are each about twelve inches long, and about twenty-four inches apart.
 7. A machine component housing having a lubricant therein and a thermocouple assembly mounted in a wall of the housing, said thermocouple assembly comprising: a thermocouple; a plurality of lead wires extending from said thermocouple; an insulating jacket extending along the length and enclosing said plurality of leads; and at least one internally sealed area within said insulating jacket to prevent fluid leakage along and within said insulating jacket, wherein areas of said insulating jacket adjacent said at least one internally sealed area have greater diameters than the internally sealed area.
 8. The machine component housing of claim 7 wherein said at least one internally sealed area comprises a plurality of internally sealed areas at longitudinally spaced locations along said insulating jacket.
 9. The machine component housing of claim 7 wherein said at least one internally sealed area is formed by a locally heated and subsequently melted portion of an additional wire extending along and within said insulating jacket.
 10. The machine component housing of claim 8 wherein said additional wire comprises a silicone wire.
 11. The machine component housing of claim 8 wherein said additional wire comprises an epoxy wire.
 12. The machine component housing of claim 8 wherein said plurality of internally sealed areas are each about twelve inches long, and about twenty-four inches apart. 